Composite Lay-Up Mold Manufacturing System

Abstract

The present invention relates to a mandrel (2) suitable for use in electrolytic surface metallization (electroplating); at least one inner coating (3) that is metallized by an electrolytic method so as to cover substantially the entire outer surface of the mandrel, thereby enabling electrical conductivity to be imparted to the surface; and at least one outer coating (4) obtained substantially entirely by electrolytic and / or electroless metallization on the inner coating (3).

Description

Technical Field

[0001] The present invention relates to a composite lay-up mold manufacturing system (or composite lay-up mold production system). By means of the composite lay-up mold manufacturing system, composite parts (or composite materials or composite members or composite parts) can be formed.

Background Art

[0002] Composite products (or composite production) are one type of materials widely used in the aerospace and defense industries worldwide (or material) . Composite materials have characteristics such as high specific strength, corrosion resistance, low coefficient of thermal expansion, and high fatigue strength, and are a preferred type of material for aerospace applications. The manufacturing of composite materials (or production) employs spraying methods, continuous forming methods, filament winding methods, resin transfer molding methods (resin transfer molding) (RTM), sheet molding / compression molding methods, and hand lay-up the methods (or hand lay-up method) . Currently, the hand lay-up of method the is commonly used in the manufacturing of aircraft (or hand lay-up method) structures. In the hand lay-up the method (or hand lay-up method) , a resin-impregnated prepreg reinforced with reinforcing materials such as carbon fiber and glass fiber is placed in a composite lay-up mold placed , and after a vacuum process, it is cured in an autoclave. The composite lay-up mold is exposed to high pressure and high temperature. Therefore, the biggest problem in the lay-up mold is thermal expansion (or thermal expansion) . in this field Currently, nickel molds are manufactured by electroforming (or electrotyping or electroforming) the methods (or electroforming method) , complex geometric member is 、 PVD (Physical Vapor Deposition) (physical vapor deposition) the methods. Electroforming (or electrotyping or electroforming) the methods (or electroforming method) are preferred because they are cost-effective is a method, and compared to PVD (Physical Vapor Deposition) (physical vapor deposition) by , with lower manufacturing simple costs for the device. These advantages (or advantage) and disadvantages(or disadvantage) Considering overall complex and large parts (or member) for use can be in mandrels the material (or material) when selecting, using stainless steel 、 will incur extra costs. Therefore, polymer-based mandrel of materials (or material) are preferred. The electroforming process (or electrotyping process or electroforming process) is carried out by coating the mandrel (or coating treatment) with a coating.

[0003] U.S. Patent No. 8394473 included in the known level of the technical field specification discloses electroplating metals such as Al, Ag, Au, Co, Ni, Pd, Sn, etc. onto polymers substrate (or polymer substrate or polymer substate) . The purpose of the coating is to provide vacuum resistance plating and fluid sealing (or vacuum resistance) for the metallized structure. Also, the coating provides wear resistance and repair advantages to the surface of the polymer structure. The usage method of the coating remaining on the surface is disclosed. (or fluid sealing)

[0004] U.S. Patent No. 2702253 included in the known level of the technical field specification discloses surface metallization (or surface metallization) . Metals such as Pd, Ni, Cr, Al, etc. in the electrolytic solution can be coated on any surface by redox reactions from a solution containing SnCl. The method of the surface metallization coating (or surface metallization coating) is disclosed.

[0005] U.S. Patent Application No. 3561995A included in the known level of the technical field discloses a method for electrically activating the polymer surface disclosure . In this method, it is disclosed that the surface of the polymer material is activated to provide a threshold conductivity level suitable for metal evaporation (or metal deposition) . this The activation process is made possible by bringing the polymer surface into contact with an activation liquid composition. This composition contains at least one reactivity modifier selected from acidic substances, salts of acidic substances, metal hydroxides, metal oxides or oxygen-containing organic substances, and ions of a metal selected from the group consisting of platinum, palladium, silver, gold, iron, nickel, cobalt, copper and rhodium. The polymer material to be metallized by activation can be polyurethane, and the material can be 、 Process (or treatment or process or method) coated with nickel at the end, as disclosed.

[0006] U.S. Patent Application No. 20030233960A1, which is included in the known state of the art in this technical field, discloses a method for subjecting a polyurethane coating to do to a surface treatment. In this method, first, the polyurethane surface is exposed to a certain type of ultraviolet sensitizer (or ultraviolet radiation sensitizer) and then to strong ultraviolet light, and further, by performing electroless coating treatment, it becomes possible to perform coating by electrolysis. Then, the obtained surface can be 、 electrolytically coated with copper, nickel, silver, or other desired metals.

Summary of the Invention

[0007] The composite lay-up mold manufacturing system developed according to the present invention (or composite lay-up mold production system) enables the production of composite lay-up molds that are fast, cost-effective, industrially applicable efficient and durable. of Manufacturing (or production) is achieved.

[0008] The object of the present invention is to manufacture a composite lay-up mold (or electrotyping method or electroforming method) by electroforming at low cost method.

[0009] Another object of the present invention separate is to obtain a composite lay-up mold that can withstand high temperatures and high pressures. (composite lay-up mold) ​

[0010] A further object of the present invention is to manufacture a mold used for manufacturing a composite part having a complicated geometric form (or solid or geometry) by a (Composite parts) (or composite member or composite material) manufacturing (or production) process that is (mold) and Simple and Rapid a (or process or method) process.

[0011] To achieve the object of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) defined (or defined) in the first claim and the claims dependent thereon includes, as a configuration, a mandrel, at least one inner coating (or inner coating), and at least one outer coating (or outer coating). The surface of the mandrel is suitable for coating by an electroforming process (or electroforming process or electroforming method or electroforming process (electroforming process)). The at least one inner coating (or inner coating) is coated on the outer surface (or outer surface) of the mandrel. By doing so, the electrical conductivity (or electrical conductivity or conductivity or electrical conductivity) of the mandrel is increased. The at least one inner coating (or inner coating) is formed (or coated) by a metallization method, and by doing so, its outer surface (or outer surface) is completely covered (or covered). The at least one outer coating (or outer coating) is formed (or coated) by electroless (or electroless) coating and / or electroforming (or electroforming or electroforming) on the uncoated surface of the inner coating.

Mode for Carrying Out the Invention

[0012] The composite lay-up mold manufacturing system (or composite lay-up mold production system) of the present invention comprises a composite lay-up mold. The composite lay-up mold is used to obtain a pre-form of a fabric (or a cloth), and is composed of an inner coating and an outer coating (as one adjacent piece (or one part (or one piece))). The composite lay-up mold is obtained by removing (or taking off) the inner coating and the outer coating from the surface of a mandrel.

[0013] In an embodiment of the present invention, the composite lay-up mold manufacturing system (or composite lay-up mold production system) comprises parts (or members). Such parts (or members) are formed by curing a fabric (or a cloth). The fabric (or a cloth) is pre-formed (or pre-shaped or pre-form) by a composite lay-up mold under the influence of temperature and pressure in a furnace.

[0014] In an embodiment of the present invention, the composite lay-up mold manufacturing system (or composite lay-up mold production system) comprises a composite lay-up mold. By such a composite lay-up mold, it becomes possible to manufacture (or produce) parts (or members) by the hand lay-up method (or hand lay-up method) (prepreg).

[0015] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes a mandrel. Such a mandrel is made of (or fabricated from) a high-density polyurethane foam material (or high-density polyurethane foam material), and the diameter (or diameter or diame-ter) of its pores (or pores) is 1 to 2 μm, and it has a geometric shape (or shape) (or form-fitting geometric shape) that fits the shape of the above-mentioned parts (or members).

[0016] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes a mandrel. Such a mandrel is made of (or fabricated from) a high-density polyurethane foam material (or high-density polyurethane foam material), and has a structure that can increase conductivity (or conductivity) by doping graphene, CNT (carbon nanotube), black carbon or a carbon derivative (or carbon derivative).

[0017] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes a mandrel. Such a mandrel has a threshold value of electrical conductivity (or electrical conductivity or conductivity or electrical conductivity) required for an inner coating that can be coated on the surface of the mandrel.

[0018] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes a mandrel. Such a mandrel is washed (or cleaned) with an alkaline solution and etched with sulfuric acid on its surface for the purpose of forming (or generating or creating) a porous structure (or porous structure or porous structure) on its surface.

[0019] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes an inner coating (or inner coating). Such an inner coating is coated on the surface of a mandrel. By doing so, the surface conductivity (or surface conductivity) of the mandrel is increased. Here, Sn +2 A mandrel immersed in a solution containing ions deposits (or deposits or deposits) Sn ions in the pores (or pores) on the surface of the mandrel to sensitize (or sensitize). Then, the mandrel is immersed in an activation solution (or activation solution or activation solution) containing Pd ions. By doing so, the Sn ions in the pores (or pores) are oxidized to Sn ions, and the Pd ions are reduced to Pd atoms. +2 ions are sensitized (or sensitized) by depositing (or depositing or depositing) Sn ions in the pores (or pores) on the surface of the mandrel. Then, the mandrel is immersed in an activation solution (or activation solution or activation solution) containing Pd +2 ions. By doing so, the Sn ions in the pores (or pores) are oxidized to Sn ions, and the Pd ions are reduced to Pd atoms. +2 ions are oxidized to Sn ions, and Pd +4 ions are reduced to Pd atoms. +2 ions are reduced to Pd atoms.

[0020] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) includes an outer coating (or outer coating). Such an outer coating is obtained by electrolysis (or electrolysis or electrolysis), and the surface of the mandrel is coated with nickel and / or nickel alloy by electrolysis (or electrolysis or electrolytic) and / or electroless (or electroless) metallization methods. By doing so, it covers (or covers) the mandrel.

[0021] Composite lay-up mold manufacturing system implemented to achieve the object of the present invention (or composite lay-up mold production system) is shown in the accompanying drawings . The drawings are as follows.

Brief Description of the Drawings

[0022]

Figure 1

Figure 2

Figure 3

[0023] All parts shown in the figures (or member) are individually assigned reference numerals, and these numerals to corresponding terms are described below 。 1. Composite lay-up mold manufacturing system (or composite lay-up mold production system) 2. Mandrel 3. Inner coating (or inner coating) 4. Outer coating (or outer coating) 5. Composite lay-up mold k. Fabric (or fabric) p. Parts (or member)

[0024] A composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) includes, as components, a mandrel (2), at least one inner coating (3), and at least one outer coating (4) (Figure 1). The mandrel (2) is suitable for use in an electroplating process (or electrodeposition process) by electrolysis (or electrolysis or electroplating). At least one inner coating (3) is metallized on the outer surface (or outer surface or outer surface) of the mandrel (2) by electrolysis (or electrolysis method or electroplating method), so that the outer surface (or the outer surface of the mandrel (2)) is almost entirely covered (or covered), thereby generating electrical conductivity (or electrical conductivity or conductivity or electrical conductivity) on the surface (or the outer surface of the mandrel (2)). At least one outer coating (4) is obtained almost entirely by electrolytic (or electrolytic) and / or electroless (or electroless) metal coating on the inner coating (3).

[0025] The composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) of the present invention includes a composite lay-up mold (5) (Figure 3). By the composite lay-up mold (5), the fabric (or fabric) (k) placed thereon can be preformed (or preformed or preformed). The composite lay-up mold (5) consists of an inner coating (3) and an outer coating (4), and is obtained by removing (or removing) the inner coating (3) and the outer coating (4) from the mandrel (2) almost entirely as a single piece (or single piece).

[0026] The composite part (or composite member or composite member or composite material) (p) is arranged on the mandrel (2) for the purpose of having a shape (or shape) (or pre-determined shape (or shape)) determined in advance by the user (or user), and its shape (or shape) (or the shape (or shape) of the mandrel (2)) is adapted (or fitted), and its surface conductivity (or surface conductivity) may be suitable for the process (or treatment or process or method) of metallization (electroplating (or electroplating)). For the purpose of providing surface conductivity (or surface conductance) to the surface of the mandrel (2), at least one inner coating (3) is obtained by coating (or covering) metal ions (or metal ions) (or pre-determined metal ions (or metal ions)) determined in advance by the user from a solution by means of an electroplating (or electroplating) process (or treatment or step or method). By doing so, at least one inner coating (or inner coating) (3) comes to cover (or cover) almost the entire outer surface (or outer surface or outer surface) of the mandrel (2). At least one outer coating (or outer coating) (4) has the shape (or shape) of the inner coating (or inner coating) (3). The outer coating (or outer coating) (4) is obtained by coating the outer surface (or outer surface or outer surface) of the inner coating (3) by means of an electrolytic (or electrolytic) and / or electroless (or electroless) metallization method. By doing so, its surface (or the surface of the inner coating (3)) comes to cover (or cover) almost the entire surface. (Figure 1)

[0027] A composite lay-up mold (5) is manufactured. The composite lay-up mold (5) is obtained by removing (or removing) the inner coating (3) and the outer coating (4) as one piece (or one part (or one piece)) from the surface of the mandrel (2). Such a part (or piece) consists of both the inner coating (3) and the outer coating (4), and when a fabric (or fabric) (k) is placed thereon, it pre-forms (or pre-forms or pre-forms) the fabric (or fabric) (k). In this way, a mold having resistance to expansion (or expansion) due to high pressure and temperature can be manufactured in an effective and simple manner. (Figure 3)

[0028] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises a part (or member) (p). The part (or member) (p) is obtained by curing a fabric (or cloth) (k). The fabric (or cloth) (k) is pre-formed (or pre-shaped or preformed) by placing it on a composite laying mold (5) under temperature and pressure. In order to form a part (or member) (p) made of a composite material (or composite or composite material), the fabric (or cloth) (k) is pre-formed (or pre-shaped or preformed) by placing it on a composite laying mold (5). The pre-formed fiber fabric (or cloth) (k) is cured in a furnace (or oven) to form a piece (or part) (p) in its final form. In this way, a part (or member) (p) made of a composite material (or composite or composite material) can be efficiently manufactured. (Figure 2)

[0029] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises a composite lay-up mold (5). The composite lay-up mold (5) is used in a hand lay-up process (or hand lay-up treatment or hand lay-up step or hand lay-up method) for a prepreg fabric (or prepreg cloth) (k). In the manufacture (or production) of a part (or member) (p) made of a composite material, the fabric (or cloth) (k) is manufactured by a hand lay-up method (or method of hand lay-up or hand lay-up method). Therefore, a composite part (or composite member or composite part or composite material) (p) can be manufactured more efficiently.

[0030] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises a mandrel (2). Such a mandrel (2) is obtained from high-density polyurethane foam, and the diameter (or diameter or diame - ter) of its pores (or pores) varies (or fluctuates or has variations) between 1 and 2 μm, and has a shape-conforming structure (or form-fitting structure) with a part (or member) (p). The mandrel (2) has a high density, and the diameter (or diameter or diame - ter) of its pores (or pores) varies (or fluctuates or has variations) between 1 and 2 μm, and is used in the manufacture (or production) of a composite lay-up mold (5). Therefore, it can be used as a robust (or robust) substrate (or substrate or sub - strate) with excellent cost-effectiveness. Such a substrate (or substrate or sub - strate) has a higher electrical conductivity (or electrical conductivity or conductivity or electrical conductivity) in the process (or treatment or step or method) of electrolysis (or electrolysis or electro - lysis), and therefore, this conductivity (or conductivity) can be increased.

[0031] In an embodiment of the present invention, a composite layup mold manufacturing system (or composite layup mold production system) (1) includes a mandrel (2). Such a mandrel (2) is made of a high-density polyurethane foam material (or high-density polyurethane foam material), and has a structure (or structure) suitable for increasing conductivity (or conductivity) by doping (or doping) different derivatives (or derivatives) of black carbon and / or carbon (or carbon), CNT (carbon nano tune) (carbon nanotube) or graphene. In addition to having a high-density structure (or high-density structure), by doping (or doping) carbon derivatives (or carbon derivatives) such as black carbon, CNT (carbon nanotube) or graphene, its conductivity (or conductivity) is increased, so that a mandrel (2) suitable for surface metal coating (or surface metal coating) by electrolysis (or electrolysis or electrolysis) is used. Therefore, this is easily provided for the process (or treatment or process or method) of metal coating by electrolysis (or electrolysis or electrolysis), and an efficient composite layup mold (5) is manufactured.

[0032] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises a mandrel (2). The value of the conductivity of such a mandrel (2) (or conductivity value or conductivity value) exceeds a threshold value at which an inner coating (or inner coating) (3) can be formed (or coated) on the surface of the mandrel (2) by electrolysis (or electrolysis or electrolys). A mandrel (2) having a surface with the electrical conductivity (or electrical conductivity or conductivity or electrical conductivity) required to form the inner coating (3) is used. Thus, by providing an effective coating by electrolysis (or electrolysis or electrolys), the inner coating (3) can be formed (or coated) on the surface of the mandrel (2) in an excellent cost-effective (or cost-effective) manner.

[0033] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises a mandrel (2). Cleaning (or cleaning) may be performed on the surface of such a mandrel (2) using an alkaline solution. Here, a porous structure (or porous structure) can be formed on the surface of the mandrel (2) by surface treatment (or surface treatment) using sulfuric acid. The porous structure (surface roughness) required to form the inner coating (3) on the surface of the mandrel (2) is intentionally formed by surface treatment using sulfuric acid. However, prior to that, a cleaning treatment (or cleaning process or cleaning method or cleaning process) with an alkaline solution is performed on the surface of the mandrel (2). Therefore, the inner coating (3) can be adsorbed on the surface of the mandrel (2) in a more cost-effective manner.

[0034] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises an inner coating (or inner coating) (3). The inner coating (3) is formed (or coated) on the surface of a mandrel (2). By doing so, its surface conductivity (or surface conductivity) increases. Here, Sn +2 The mandrel (2) immersed in a solution containing Sn ions is sensitized (or sensitized) by the deposition (or deposition or deposition) of Sn ions in the pores (or pores) on the surface of the mandrel (2), and the surface of such a sensitized mandrel (2) is immersed in an activation solution (or activation solution or activation solution) containing Pd +2 ions. By doing so, the Sn ions in the pores (or pores) are oxidized to Sn ions, and the Pd ions are reduced to Pd atoms. By exposing the mandrel (2) to a solution containing Sn ions and filling (or filling) the open pores (or pores) on its surface, after the sensitization treatment (or sensitization process or sensitization method or sensitization process) of the mandrel (2), the mandrel (2) is immersed in an activation solution (or activation solution or activation solution) containing Pd +2 ions. By doing so, the Sn ions in the pores (or pores) are oxidized to Sn ions, and the Pd ions are reduced to Pd atoms. By doing so, the surface of the mandrel (2) is coated by the inner coating (3). As a result, its surface conductivity (or surface conductivity) increases. Therefore, the outer coating (or outer coating) (4) can take the shape (or shape) of the mandrel (2). Note that the outer coating (or outer coating) (4) is part of the coating composite lay-up mold (5). +2 ​ +4 ​ +2 ​ +2 ​ +2 ​ +2 ​ +4 ​ +2 ​

[0035] In an embodiment of the present invention, a composite lay-up mold manufacturing system (or composite lay-up mold production system) (1) comprises an outer coating (or outer coating) (4). Such an outer coating (or outer coating) (4) is obtained by coating the inner coating (3) almost entirely with nickel and / or nickel alloy by means of electroless metallization (or electroless metallization) and / or electroforming (or electroforming or electrolitic electroforming) methods (or electroforming method). The outer coating (4) is obtained by coating the inner coating (3) with nickel and / or nickel alloy using methods by electroless (or electroless) and / or electrolytic (or electrolysis or electrolitic) means. These are necessary to obtain the composite lay-up mold (5) and are predetermined (or pre-determined) by the user (or user). Therefore, the composite lay-up mold (5) is manufactured efficiently.

Claims

1. A composite lay-up mold manufacturing system (1) for use in an electrodeposition process by electrolysis, comprising: a mandrel (2); at least one inner coating (3) metallized on the outer surface of the mandrel (2) so as to substantially entirely cover the outer surface thereof to generate electrical conductivity on the surface; and at least one outer coating (4) obtained substantially entirely by an electrolytic or electroless metal coating on the inner coating (3), wherein the mandrel (2) is made of a high-density polyurethane foam material and has its conductivity increased by doping with black carbon and / or different derivatives of carbon, CNT (carbon nanotube) or graphene; Sn ＋２ Sn ions are introduced into the pores on the surface of the mandrel (2) immersed in a solution containing Sn ions ＋２ to sensitize the surface of the mandrel (2), and Pd ions are immersed in a solution containing Pd ions and used in the pores of the mandrel (2) for activation ＋２ Sn ions are oxidized to Sn in the pores of the mandrel (2), and Pd ions are reduced to Pd atoms to coat the surface of the mandrel (2) and increase the surface conductivity of the inner coating (3); and ＋２ ions ＋４ to ＋２ coat the surface of the mandrel (2) to increase the surface conductivity of the inner coating (3); and a composite lay-up mold (5) which allows a laid fabric (k) to be formed, consists of the inner coating (3) and the outer coating (4), and is obtained by removing the inner coating (3) and the outer coating (4) from the mandrel (2) substantially entirely as a single piece, characterizing the composite lay-up mold manufacturing system (1).

2. The composite lay-up mold manufacturing system (1) according to Claim 1, characterized by a configuration for manufacturing a part (p) by applying a curing method under temperature and pressure to a fabric (k) formed by being placed on the composite lay-up mold (5).

3. The composite lay-up mold manufacturing system (1) according to Claim 1 or 2, characterized by the composite lay-up mold (5) used in the hand lay-up process of a prepreg fabric (k).

4. The composite lay-up mold manufacturing system (1) according to any one of Claims 1 to 3, characterized by the mandrel (2) having a conductivity value exceeding a threshold at which the inner coating (3) can be coated on the surface of the mandrel (2).

5. The composite lay-up mold manufacturing system (1) according to any one of Claims 1 to 4, characterized by the outer coating (4) obtained by substantially entirely coating the inner coating (3) with nickel and / or a nickel alloy by electroless metallization or an electrolytic electroforming method.

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